An intelligent monitor for roller rods in roller-hearth heating furnaces

Abstract

This application discloses an intelligent monitor for rollers in roller-hearth heating furnaces, comprising a monitor body and a fixing mechanism for mounting the monitor body below the monitored roller. The monitor body includes a composite roller that closely contacts the roller surface of the monitored roller and rotates with it; a swing mechanism disposed on one side of the composite roller for supporting it; and a roller motion state detection mechanism disposed below the composite roller for monitoring the operating state of the monitored roller through the rotation of the composite roller. The intelligent monitor for rollers in roller-hearth heating furnaces provided in this application requires no equipment modification, is easy to install, can accommodate rollers of varying diameters, and provides comprehensive detection capabilities. The present invention can not only identify roller breakage faults, but also faults such as slippage and overheating based on speed changes. Furthermore, the monitor can generate power through its own rotating mechanism, ensuring long-term stable operation of the equipment.

Description

Technical Field

[0001] The present application relates to the technical field of hot forming production lines and roller-hearth heating furnaces, and in particular to an intelligent monitor for rollers of roller-hearth heating furnaces. Background Art

[0002] As the country with the largest automobile production and ownership in the world, China is facing increasingly serious pollution caused by automobile exhaust. Therefore, automobile lightweighting technology has become one of the mainstream technologies in the development of passenger vehicles.

[0003] Aluminum alloy and ultra-high-strength steel hot forming technologies are two major areas of focus in automotive lightweighting. Ultra-high-strength steel is the most widely used of these technologies. Furthermore, after several years of development, hundreds of production lines are now in operation both domestically and internationally.

[0004] One of the key pieces of equipment in the hot forming production line is the roller-hearth heating furnace. These ceramic rollers, with each unit equipped with over 300, can stall due to corrosion, chain breakage, tooth skipping, and other factors. Manual inspections are essential to detect these faults promptly, otherwise they can cause material overlap and dropout, impacting the stable operation of the entire line.

[0005] Currently, most companies rely on manual inspections to monitor roller operation. These typically involve three people overseeing the entire production line: one responsible for operating the equipment at the end of the line, and two responsible for unloading the material at the end of the line. Relying on operators for inspections or increasing the number of personnel required to perform inspections reduces production efficiency and increases labor costs.

[0006] Some foreign companies monitor rollers by installing proximity switches at the non-drive end of each roller. This method requires numerous signal lines and is costly. These signals must be connected to a PLC, occupying numerous input nodes. This method is also unsuitable for intelligent retrofitting of older equipment. Summary of the Invention

[0007] Based on the above deficiencies in the existing technology, the technical problem to be solved by this application is to provide an intelligent monitor for rollers of a roller-bottom heating furnace, which does not require any equipment modification, is easy to install, can adapt to rollers of different diameters, and provides comprehensive detection.

[0008] The present application provides an intelligent monitor for rollers of a roller-bottom heating furnace, comprising a monitor body and a fixing mechanism for mounting the monitor body below the monitored roller, wherein the monitor body is provided with: a composite roller, which is in close contact with the roller surface of the monitored roller and rotates along with the monitored roller; a swing mechanism, which is arranged on one side of the composite roller and is used to support the composite roller; and a roller motion state detection mechanism, which is arranged below the composite roller and is used to monitor the working state of the monitored roller through the rotation of the composite roller.

[0009] Furthermore, the roller motion state detection mechanism includes: a spring contact piece, which extends into the gear dial on the top layer of the composite roller, and when the gear dial rotates, it dials the spring contact piece, causing the spring contacts to contact each other and generate electrical signals; a logic operation module, which is connected to the spring contact piece and is used to receive different electrical signals generated by the spring contact piece, and to calculate and judge whether the monitored roller is moving normally; an indicator light, which is connected to the logic operation module and is used to display the judgment result of the logic operation module.

[0010] Furthermore, the roller motion state detection mechanism further includes: a wireless signal transmitting module connected to the logic operation module, and configured to transmit the electrical signal generated by the spring contact piece to the control terminal.

[0011] From the above, the fault signal can be sent wirelessly through the wireless signal transmission module, without the need for external signal lines, reducing investment costs and standardizing and tidying the workshop.

[0012] Furthermore, the monitor of the present application also includes: a rechargeable power supply for providing electrical energy for the operation of the monitor; a generator, connected to the rechargeable power supply, whose driving gear is engaged with the gear of the middle layer of the composite roller, generates electrical energy under the drive of the composite roller, and replenishes electrical energy for the rechargeable power supply.

[0013] Optionally, the swing mechanism includes: a composite roller rocker arm, one end of which is hinged to the monitor body, and the other end of which is equipped with the composite roller; a tightening spring, which is arranged below the composite roller rocker arm and tightens the composite roller rocker arm so that the composite roller can be tightly attached to the monitored roller rod.

[0014] As described above, the composite roller can be brought into close contact with the monitored roller by the swing mechanism without affecting the normal operation of the roller, so as to monitor the working state of the roller.

[0015] Furthermore, it also includes an infrared temperature measurement module installed in the monitor body, which is arranged toward the monitored roller rod and is used to output the detected heat signal to the wireless signal transmission module and send an alarm signal that the monitored roller rod is overheated.

[0016] Optionally, the fixing mechanism includes: a magnetic suction cup, which can be adsorbed on the equipment housing near the monitored roller; a guide stud, which is vertically fixed on the magnetic suction cup and passes through the monitor body; a locking nut, which is rotatably fastened on the guide stud and is located at the top and bottom of the monitor body to lock the monitor body in an appropriate position on the guide stud.

[0017] As described above, the monitor can be conveniently fixed by the fixing mechanism without modifying the original equipment, and the installation is convenient.

[0018] Furthermore, an adjustment mechanism is provided above the swing mechanism, which includes: a connecting rod, one end of which is away from the composite roller and is connected to the long strip through hole of the composite roller rocker; an adjustment wheel, which is installed at the other end of the connecting rod and fits tightly with the monitored roller and the composite roller under the adjustment of the connecting rod.

[0019] From the above, the adjustment mechanism can be used as a supplement to prevent the composite roller from fitting loosely due to installation reasons.

[0020] Optionally, the housing of the monitor body is a transparent shell, and the composite roller, the swing mechanism and the roller motion state detection mechanism are all installed inside the transparent shell.

[0021] Furthermore, the outer surface of the composite roller is coated with stripes of different colors.

[0022] From the above, the roller hearth heating furnace roller intelligent monitor of the present invention has at least the following beneficial effects:

[0023] 1. Strong adaptability: Whether new or old equipment, regardless of roller diameter or installation angle, the intelligent monitor of the present invention can be installed to monitor the roller's operating status. This device has a built-in rechargeable power supply and can generate electricity through the rotation of the roller, ensuring long-term stable operation of the equipment.

[0024] 2. Multiple alarm methods, safe and reliable: The monitor uses a transparent shell, and the rotating composite roller adopts a striped appearance of different colors, which is eye-catching and easy to identify. It has a built-in two-color indicator light, which clearly shows the normal and fault status. The alarm signal can be sent wirelessly, without the need for external signal cables.

[0025] 3. One machine with multiple uses and comprehensive detection: By integrating temperature, speed and other monitoring devices on the monitor microcontroller, it can not only identify roller breakage faults, but also identify slippage, overheating and other faults based on speed changes. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 This is a schematic diagram of the structure of the intelligent monitor for rollers in a roller-hearth heating furnace provided in Example 1 of the present application;

[0027] Figure 2 This is a structural diagram of the intelligent monitor for roller rods in a roller-hearth heating furnace provided in Example 2 of the present application.

[0028] Figure numerals: 10-monitor body; 11-transparent shell; 21-magnetic suction cup; 22-guide stud; 23-locking nut; 30-monitored roller; 40-compound roller; 41-compound roller rocker; 42-tensioning spring; 43-adjusting wheel; 44-connecting rod; 45-long strip through hole; 51-spring contact piece; 52-logic operation module; 53-red indicator light; 54-green indicator light; 60-generator; 61-rechargeable power supply; 70-wireless signal transmission module; 80-infrared temperature measurement module; 90-circuit board. DETAILED DESCRIPTION

[0029] The present application is further described in detail below through specific embodiments and in conjunction with the accompanying drawings.

[0030] Example 1

[0031] like Figure 1 As shown, the first embodiment of the present application provides an intelligent monitor for rollers in roller-hearth heating furnaces. This monitor can be used to monitor the operating status of rollers of various shapes. Regardless of the equipment, diameter, or installation angle, the monitor can be installed at the non-drive end of the roller to monitor its operating status. The intelligent monitor consists of a monitor body 10, a magnetic suction cup 21 with a guide stud 22, and a locking nut 23. The guide stud 22 is mounted on the magnetic suction cup 21. The magnetic suction cup 21 can be attached to the equipment (steel) housing near the monitored roller 30. The monitor body 10 can move up and down along the guide stud 22, and the locking nut 23 locks the monitor body 10 in place on the guide stud 22. Once fixed, the composite roller 40 on the monitor body 10 adheres closely to the roller surface below the monitored roller 30, rotating with the roller under the action of friction to monitor the roller's operating status.

[0032] In order to ensure that the composite roller 40 can always be in close contact with the monitored roller rod 30, a swing mechanism is set on one side of the composite roller 40, and the monitored roller rod 30 is supported by the composite roller rocker 41, and the composite roller rocker 41 is supported by a tensioning spring 42. The tensioning spring 42 is in a compressed state and pushes the composite roller rocker 41 upward through its elastic force, so that the composite roller 40 at the free end of the composite roller rocker 41 can always be in close contact with the monitored roller rod 30. The other end of the composite roller rocker 41 is hinged to the monitor body 10.

[0033] Furthermore, the composite roller 40 of the present invention has a three-layer structure. The top layer is a toothed paddle wheel with circumferentially evenly distributed protruding teeth. Rotation of the paddle wheel moves the spring contacts 51, causing them to contact each other and generate an electrical signal. The middle layer is a gear that meshes with the drive gear of the generator 60, driving the generator 60 to rotate and generate electricity. The bottom layer is a cylindrical roller that conforms to the surface of the monitored roller 30 and rotates with it, simultaneously driving the toothed paddle wheel and the gears in the middle layer. The rotation of the composite roller 40 is used to monitor the operating status of the monitored roller 30.

[0034] The rotation, non-rotation, and slipping states of the monitored roller 30 generate different electrical signals via the spring contact 51. These signals are then evaluated by the logic operation module 52 to determine whether the monitored roller 30 is moving normally, which is then displayed via the red indicator light 53 or the green indicator light 54. Furthermore, the operating signal can be transmitted to the control terminal via the wireless signal transmission module 70. The wireless signal transmission module 70 of the present invention can be a model F05R wireless signal transmission module for transmitting signal data.

[0035] The spring contact piece 51 , the logic operation module 52 , the indicator light and the wireless signal transmission module 70 constitute the roller motion state detection mechanism of the present invention, which is used to monitor the working state of the monitored roller 30 .

[0036] The logic operation module 52 is responsible for processing input signals and outputting calculation results. The rotation of the composite roller 40 shifts the spring contact 51, causing it (like a push button switch) to generate a periodic signal. This signal is then input into the logic operation module 52 for calculation. When the roller is rotating, a periodic signal is generated. When the roller is not rotating, no signal is generated, or a constant signal is generated. The logic operation module is used to distinguish between these three types of signals. If the signal is periodic, the logic operation module outputs a "true" result and illuminates the green indicator light 54, indicating that the roller is operating normally. If the signal is non-periodic, the logic operation module outputs a "false" result and illuminates the red indicator light 53, indicating that the roller has malfunctioned. The logic operation module 52 can be composed of devices such as FPGAs (field programmable gate arrays) and transistors to implement logical judgment.

[0037] Additionally, a rechargeable power supply 61 is located within the monitor body 10 to ensure long-term, stable operation. For initial use, the rechargeable power supply 61 can be fully charged. During operation, the gear-driven generator 60 in the middle layer of the composite roller 40 generates electricity to supplement the rechargeable power supply 61.

[0038] The monitor body 10 provided in the embodiment of the present application is also provided with an infrared temperature measurement module 80. The infrared temperature measurement module 80 can adopt an infrared temperature measurement module with model HW-691. The infrared temperature measurement module 80 is installed near the composite roller 40 and faces the monitored roller 30 to facilitate measuring the temperature of the roller. It is connected to the circuit board 90 through wiring, and can output the detected thermal signal of the monitored roller 30 to the wireless signal transmission module 70. When the monitored roller 30 is overheated, an alarm signal will be issued.

[0039] In addition, the logic operation module 52 , the red indicator light 53 , the green indicator light 54 , the rechargeable power supply 61 and the wireless signal transmission module 70 are all integrated on the circuit board 90 .

[0040] The monitor body 10 utilizes a transparent housing 11. The aforementioned composite roller rocker 41, tensioning spring 42, composite roller 40, infrared temperature measurement module 80, circuit board 90, spring contact 51, and generator 60 are all mounted within the transparent housing 11, collectively forming the monitor body. The outer surface of the rotating composite roller 40 is coated with stripes of different colors, preferably yellow and black. The operation of its internal components can be clearly seen through the transparent housing 11, making it easily identifiable. The dual-color indicator light is also clearly visible through the transparent housing 11, clearly indicating normal and fault conditions.

[0041] Example 2

[0042] like Figure 2 As shown, the second embodiment of the present application differs from the first embodiment in that an adjustment mechanism is provided above the swing mechanism. An adjustment wheel 43 is bolted to the elongated through-hole 45 of the composite roller rocker 41 via a connecting rod 44. The lower end of the connecting rod 44 is fixed to the elongated through-hole 45 in an adjustable position, enabling the upper end of the adjustment wheel 43 to be adjusted vertically. The adjustment wheel 43 can be adjusted along the elongated through-hole 45 to achieve vertical movement. If, after adjustment of the position by the guide stud 22 of the fixing mechanism, the composite roller 40 and the monitored roller 30 do not fit tightly together, the position of the adjustment wheel 43 can be fine-tuned to achieve a tight fit between the roller and the composite roller 40, thereby increasing friction, ensuring transmission accuracy, and guaranteeing monitoring quality.

[0043] As can be seen from the technical solutions of the aforementioned embodiments of the present invention, the intelligent monitoring device for heating furnace rollers provided by the present invention can be freely attached near the roller being monitored, eliminating the need for equipment modification and facilitating installation. The monitor's composite rollers adhere closely to the roller surface, accommodating rollers of varying diameters and offering a wide range of applications.

[0044] The above description is merely a preferred embodiment of the present application and is not intended to limit the present application. Persons skilled in the art will readily appreciate that various modifications and variations are possible. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of the present application shall be included within the scope of protection of the present application.

Claims

1. An intelligent monitor for rollers of a roller-hearth heating furnace, comprising a monitor body (10) and a fixing mechanism for mounting the monitor body (10) below a monitored roller (30), characterized in that: The monitor body (10) is provided with: The composite roller (40) is in close contact with the roller surface of the monitored roller (30) and rotates along with the monitored roller (30); a swing mechanism, arranged on one side of the composite roller (40) and used for supporting the composite roller (40); A roller motion state detection mechanism is provided below the composite roller (40) and is used to monitor the working state of the monitored roller (30) through the rotation of the composite roller (40); The composite roller (40) has a three-layer structure, the top layer is a toothed wheel, and the toothed wheel has convex teeth evenly distributed in the circumferential direction; The roller motion state detection mechanism includes: The spring contact piece (51) extends into the toothed paddle wheel on the uppermost layer of the composite roller (40), and when the toothed paddle wheel rotates, the spring contact piece (51) is moved, so that the spring contact pieces (51) contact each other to generate an electrical signal; A logic operation module (52) is connected to the spring contact piece (51) and is used to receive different electrical signals generated by the spring contact piece (51), and to calculate and judge whether the monitored roller (30) is moving normally; an indicator light connected to the logic operation module (52) and used to display the judgment result of the logic operation module (52); Also includes: a rechargeable power supply (61) for providing power for the operation of the monitor; a generator (60) connected to the rechargeable power source (61), wherein the driving gear of the generator (60) is meshed with the gear of the middle layer of the composite roller (40), and generates electric energy under the drive of the composite roller (40) and replenishes electric energy for the rechargeable power source (61); The swing mechanism comprises: A composite roller rocker (41), one end of which is hinged to the monitor body (10), and the other end of which is mounted with the composite roller (40); A tightening spring (42) is provided below the composite roller swing rod (41) and tightens the composite roller swing rod (41) so that the composite roller (40) can be in close contact with the monitored roller rod (30); An adjusting mechanism is provided above the swing mechanism, which comprises: A connecting rod (44), one end of which is away from the composite roller (40) and is connected to the long strip through hole (45) of the composite roller rocker (41); The regulating wheel (43) is mounted on the other end of the connecting rod (44), and is tightly fitted to the monitored roller (30) and the composite roller (40) under the regulation of the connecting rod (44).

2. The roller hearth heating furnace roller intelligent monitor according to claim 1 is characterized in that: The roller motion state detection mechanism also includes: The wireless signal transmitting module (70) is connected to the logic operation module (52) and is used to transmit the electrical signal generated by the spring contact piece (51) to the control terminal.

3. The intelligent monitor for rollers in a roller-hearth heating furnace according to claim 2, characterized in that: The device also includes an infrared temperature measurement module (80) installed in the monitor body (10), the infrared temperature measurement module (80) being arranged toward the monitored roller (30) and configured to output a detected heat signal to the wireless signal transmission module (70) and to issue an alarm signal indicating that the monitored roller (30) is overheated.

4. The roller hearth heating furnace roller intelligent monitor according to claim 1, characterized in that: The fixing mechanism comprises: A magnetic suction cup (21) can be attached to a device housing near the monitored roller (30); A guide stud (22) is vertically fixed on the magnetic chuck (21) and passes through the monitor body; Locking nuts (23) are rotatably fastened to the guide studs (22) and are located at the top and bottom of the monitor body to lock the monitor body in a proper position on the guide studs (22).

5. The intelligent monitor for rollers in a roller-hearth heating furnace according to claim 1, characterized in that: The housing of the monitor body (10) is a transparent shell (11), and the composite roller (40), the swing mechanism and the roller motion state detection mechanism are all installed inside the transparent shell (11).

6. The roller hearth heating furnace roller intelligent monitor according to claim 1, characterized in that: The outer surface of the composite roller (40) is coated with stripes of different colors.

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